YALE (B876) GDP100DB LIFT TRUCK Service Repair Manual

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  • Service Repair GDP80-120DB [B876]; GDP130-160EB [B877]

    PART NO. 524150798 8000 YRM 940

  • 8000 YRM 940 Lift Truck Weights

    Lift Truck Weights Unit kg lb

    GP170DB 11,735 25,872

    GDP80DB (GP190DB) 11,928 26,296

    GDP90DB (GP210DB) 12,508 27,572

    GDP100DB (GP230DB) 14,144 31,178

    GP250DB 14,343 31,621

    GDP120DB (GP280DB) 15,787 34,800

    GDP130EB (GP300EB) 16,669 36,753

    GDP140EB (GP330EB) 17,826 39,303

    GDP160EB (GP360EB) 18,710 41,253

    GDP80-120DB (GP170-280DB) models: 5335 mm (210 in.) mast, 2350 mm (92.5 in.) standard carriage, 65 [70] × 200 × 1220 mm (2.6 [2.76] × 8 × 48 in.) forks.

    GDP130-160EB (GP300-360EB) models: 5310 mm (209 in.) mast, 2502 mm (98.5 in.) standard carriage, 90 × 200 × 1375 mm (3.5 × 8 × 54 in.) forks.

    1

  • Capacities 8000 YRM 940

    Capacities Item Quantity

    Engine Oil, Perkins Diesel 1006-60, With Oil Filter 13.2 liter (13.9 qt)

    Engine Oil, Perkins 1006-60T, With Oil Filter 14.2 liter (15 qt)

    Engine Oil, Perkins 1106C-E60 TA Tier 2, With Oil Filter 14.2 liter (15 qt)

    Engine Oil, Cummins QSB5.9-30 and B LPG Plus, With Oil Filter

    16.3 liter (17.2 qt)

    Cooling System, Perkins 1006-60 26 liter (27.5 qt)

    Cooling System, Perkins 1006-60T 31 liter (32.8 qt)

    Cooling System, Perkins 1106C-E60 TA Tier 2 25.5 liter (27 qt)

    Cooling System, Cummins 25.5 liter (27 qt)

    Hydraulic Tank (FULL mark)

    GDP80-120DB (GP170-280DB) 109 liter (28.8 gal)

    GDP130-160EB (GP300-360EB) 109 liter (28.8 gal)

    Hydraulic System (Total Capacity)

    GDP80-120DB (GP170-280DB) 139 liter (36.7 gal)

    GDP130-160EB (GP300-360EB) 139 liter (36.7 gal)

    Transmission 16.5 liter (17.4 qt)

    Drive Axle and Differential

    Dry Brake System

    GDP80-120DB (GP170-280DB) 19 liter (20 qt)

    GDP130-160EB (GP300-360EB) 21 liter (21.1 qt)

    Wet Brake System

    GDP80-120DB (GP170-280DB) 19 liter (20 qt)

    GDP130-160EB (GP300-360EB) 21 liter (21.1 qt)

    Planetary Gears

    GDP80-120DB (GP170-280DB) 2.8 liter (3.0 qt) each

    GDP130-160EB (GP300-360EB) 2.4 liter (2.5 qt) each

    Fuel Tank (Diesel Engines) 128 liter (33.8 gal)

    LPG Tank LPG HD-10 77 liter (20.3 gal)

    2

  • 8000 YRM 940 Engine Specifications

    Engine Specifications PERKINS DIESEL

    Item Specification

    Type Perkins 1006-60, 1006-60T and 1106C-E60 TA, Tier 2

    Numbers of Cylinders 6

    Firing Order 1-5-3-6-2-4

    Bore 100 mm (3.937 in.)

    Stroke 127 mm (5.000 in.)

    Displacement 6 liter (366 in.3)

    Compression Ratio 17.25:1

    Oil Pressure (Minimum, at 2200 rpm and normal operating temperature)

    280 kPa (40 psi)

    Governed Speed (Full power and normal operating temperature)

    1006-60 2200 rpm with load, 2310 ±50 no load

    1006-60T 2300 rpm with load, 2415 ±50 no load

    Governed Speed (To high idle)

    1106C-E60 TA, Tier 2 2415 ±10

    Idle Speed

    1006-60 725 to 775 rpm

    1006-60T 725 to 775 rpm

    1106C-E60 TA, Tier 2 740 to 760 rpm

    Stall Speed (Broken-in Engine)

    1006-60 1925 ±50 rpm

    1006-60T/1106C-E60 TA, Tier 2 2095 ±50 rpm

    Fuel Injection Timing 23° BTDC (Static)

    Thermostat

    Begin to open 80 to 84°C (176 to 183°F)

    Fully open 96°C (205°F)

    Valve Clearance (Cold)

    Intake 0.20 mm (0.008 in.)

    Exhaust 0.45 mm (0.018 in.)

    3

  • Engine Specifications 8000 YRM 940

    CUMMINS DIESEL/LPG

    Item Specification

    Type Cummins B LPG Plus Cummins QSB5.9-30

    Number of Cylinders 6 6

    Firing Order 1-5-3-6-2-4 1-5-3-6-2-4

    Bore 102 mm (4.02 in.) 102 mm (4.02 in.)

    Stroke 120 mm (4.62 in.) 120 mm (4.62 in.)

    Displacement 5.88 liter (359 in.3) 5.88 liter (359 in.3)

    Compression Ratio 9.25:1 18:1

    Oil Pressure (Minimum, at 2500 rpm and normal operating temperature)

    345 kPa (50 psi) 345 kPa (50 psi)

    Oil Pressure (At low idle) 69 kPa (10 psi) 69 kPa (10 psi)

    Governed Speed (Full power at Normal Operating Temperature)

    GDP80-120DB, GDP130-160EB 2500 rpm with load 2600 ±50 no load

    2300 rpm with load 2450±30 no load

    GP170-280DB, GP300-360EB 2500 rpm with load 2600 ±50 no load

    2500 rpm with load 2600±50 no load

    Idle Speed 850 rpm±2% 725 ±2%

    Stall Speed (Broken-in Engine) 1950 to 2100 rpm 1950 to 2100 rpm

    Thermostat

    Begin to open 83°C (181°F) 83°C (181°F)

    Fully open 91°C (196°F) 91°C (196°F)

    Valve Clearance (Cold)

    Intake 0.305 mm (0.012 in.) 0.25 mm (0.01 in.)

    Exhaust 0.61 mm (0.024 in.) 0.51 mm (0.02 in.)

    4

  • 8000 YRM 940 Hydraulic System

    Hydraulic System Item Quantity

    Perkins Hydraulic Pump Capacity @ 2300 rpm for turbo, 2200 rpm for nonturbo

    Main Section @ 21 MPa (3045 psi)

    1006-60T/1106C-E60 TA 192 liter/min (51 gal/min)

    1006-60 160 liter/min (42.3 gal/min)

    Steering/Aux Section @ 19.3 MPa (2800 psi)

    1006-60T/1106C-E60 TA 93 liter/min (24.6 gal/min)

    1006-60 78 liter/min (20.6 gal/min)

    Cummins Diesel Hydraulic Pump Capacity @ 2300 rpm

    Main Section @ 21 MPa (3045 psi) 192 liter/min (51 gal/min)

    Steering/Aux Section @ 19.3 MPa (2800 psi) 93 liter/min (24.6 gal/min)

    Cummins LPG Hydraulic Pump Capacity @ 2500 rpm

    Main Section @ 21 MPa (3045 psi) 183 liter/min (48.3 gal/min)

    Steering/Aux Section @ 19.3 MPa (2800 psi) 89 liter/min (23.5 gal/min)

    Relief Pressures *

    Main Control Valve

    Lift Circuit 21.0 MPa (3045 psi)

    Tilt and Auxiliary Circuits 19.3 MPa (2800 psi)

    Steering Circuit 16.5 MPa (2400 psi)

    ECH Functions 14.0 MPa (2030 psi)

    *Oil temperature 60°C (140°F)

    5

  • Tire Sizes 8000 YRM 940

    Electrical System All Models 24 Volt, Negative Ground

    Alternator Output at 24°C (75°F)

    21 amps at 750 rpm All Engines

    76 amps at 2200 rpm

    Tire Sizes NOTE: Refer to Truck Nameplate for correct tire pres- sure.

    Model Tire Size Tire Pressure

    GDP80-90DB (GP170-210DB) 9.00 × 20-12 ply 690 kPa (100 psi)

    GDP80-90DB (GP170-210DB) 9.00 × 20-14 ply 900 kPa (130 psi)

    GDP100-120DB (GP230-280DB) 10.00 × 20-12 ply 690 kPa (100 psi)

    GDP100-120DB (GP230-280DB) 10.00 × 20-16 ply 900 kPa (130 psi)

    GDP130EB (GP300EB) 11.00 × 20-14 ply 690 kPa (100 psi)

    GDP130-160EB (GP300-360EB) 12.00 × 20-16 ply 1000 kPa (145 psi)

    All Michelin XZM Radial Tires 1000 kPa (145 psi)

    6

  • 8000 YRM 940 Mast Speeds

    Mast Speeds PERKINS DIESEL

    Lifting Lifting Lifting Lowering

    1006.60 1006.60T 1106C-E60 TA 1006.60, 1006.60T and 1106C-E60 TA

    No Load RatedLoad No Load Rated Load No Load

    Rated Load No Load

    Rated Load

    Unit

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    GP170DB 0.63 124 0.41 80 0.73 143 0.48 96 0.73 143 0.48 96 0.48 95 0.50 98

    GDP80DB (GP190DB)

    0.63 124 0.41 80 0.73 143 0.48 96 0.73 143 0.48 96 0.48 95 0.50 98

    GDP90DB (GP210DB)

    0.63 124 0.41 80 0.73 143 0.48 96 0.73 143 0.48 96 0.48 95 0.50 98

    GDP100DB (GP230DB)

    0.53 104 0.36 70 0.56 110 0.38 74 0.53 104 0.34 67 0.46 91 0.49 97

    GP250DB 0.53 104 0.36 70 0.56 110 0.38 74 0.53 104 0.34 67 0.46 91 0.49 97

    GDP120DB (GP280DB)

    0.53 104 0.36 70 0.56 110 0.38 74 0.53 104 0.34 67 0.46 91 0.49 97

    GDP130EB (GP300EB)

    - - - - 0.46 91 0.30 59 0.44 87 0.29 57 0.44 87 0.48 95

    GDP140EB (GP330EB)

    - - - - 0.46 91 0.30 59 0.44 87 0.29 57 0.44 87 0.48 95

    GDP160EB (GP360EB)

    - - - - 0.46 91 0.30 59 0.44 87 0.29 57 0.44 87 0.48 95

    7

  • Mast Speeds 8000 YRM 940

    CUMMINS DIESEL/LPG

    Lifting Lifting Lowering

    B LPG Plus QSB5.9-30 B LPG Plus/QSB5.9-30

    No Load Rated Load No Load Rated Load No Load Rated LoadUnit

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    m/ sec

    ft/ min

    GP170DB 0.69 136 0.37 73 0.73 143 0.48 95 0.48 95 0.50 98

    GDP80DB (GP190DB)

    0.69 136 0.37 73 0.73 143 0.48 95 0.48 95 0.50 98

    GDP90D (GP210DB)

    0.69 136 0.37 73 0.73 143 0.48 95 0.48 95 0.50 98

    GDP100DB (GP230DB)

    0.50 98 0.26 51 0.53 104 0.46 91 0.46 91 0.49 97

    GP250DB 0.50 98 0.26 51 0.53 104 0.46 91 0.46 91 0.49 97

    GDP120DB (GP280DB)

    0.50 98 0.26 51 0.53 104 0.46 91 0.46 91 0.49 97

    GDP130EB (GP300EB)

    0.41 81 0.22 43 0.44 87 0.29 57 0.44 87 0.48 95

    GDP140EB (GP330EB)

    0.41 81 0.22 43 0.44 87 0.29 57 0.44 87 0.48 95

    GDP160EB (GP360EB)

    0.41 81 0.22 43 0.44 87 0.29 57 0.44 87 0.48 95

    8

  • 8000 YRM 940 Torque Specifications, Perkins Diesel

    Torque Specifications, Cummins Diesel LUBRICATION SYSTEM

    Plug, Oil Sump, Aluminum Oil Pan 60 N•m (44 lbf ft)

    Plug, Oil Sump, Steel Oil Pan 80 N•m (59 lbf ft)

    All other Torque Specifications are found in Cummins Engine Manual. Contact Cummins Engine for any torque specifications not listed for this engine.

    Torque Sp